Compressing and unifying food in aluminum foil molds

ABSTRACT

An aluminum foil mold is placed in a rigid back-up mold with a cavity matching the contour of the foil mold. Fluid food deposited in the foil mold is compressed therein by a mold top that is pressed down against the back-up mold. Heat applied to the back-up mold and mold top flows to the foil mold and fluid food therein to effect baking under pressure. Thus, a unified food product is formed in the foil mold that can protect the food product against handling damage until it is eaten. A foil mold of novel design is used to form a food product shaped like an upside-down pizza shell.

This is a division of application Ser. No. 09/369,161, filed Aug. 5,1999, now U.S. Pat. No. 6,240,836.

BACKGROUND OF THE INVENTION

This invention relates to an apparatus and method of molding fluid foodsby compression and baking them under pressure. More particularly, theinvention involves an aluminum foil mold which is filled with a fluidfood that is compressed and baked under pressure into an edible coherentshape.

In recent years. U.S. Pat. Nos. 4,693,900 to Molinari and 5,283,071 and5,411,752 to Taylor et al have proposed the formation of coherentproducts composed of cooked spaghetti and a binding agent. The methodsdisclosed in these patents are not suited for rapid production ofcoherent food products in a large-scale operation. The formation ofshaped food products from rice and other cereal grains is illustrated inU.S. Pat. Nos. 3,711,295; 3,961,087 and 5,137,745 to Zukerman, but noneof these patents suggest any aspect of this invention.

Accordingly, a principal object of the invention is to provide anapparatus and method for molding and baking fluid food under pressureinto edible unified shapes.

Another important object is to provide an aluminum foil mold in whichfluid food is converted into a desired shaped product, and which servesto protect the shaped food product from handling and shipping damage.

A further object is to provide apparatus that can be automated withminimum mechanical movements.

These and other features and advantages of the invention will beapparent from the description which follows.

SUMMARY OF THE INVENTION

In accordance with this invention, the primary mold is preformedaluminum foil, preferably having a multiplicity of needle punctures thatact as vents for volatiles and steam generated during the baking of thefluid food under compression in the foil mold. A secondary or back-upmold having a recess or cavity that nests with the foil mold serves toprevent distortion of the foil mold during compression of the foodtherein and to facilitate the transfer of heat to the foil mold and itscontained food. The back-up mold which is formed of rigid metal,preferably aluminum, is heated by gas flames beneath the mold, or bysteam or hot liquid flowing through coils attached to the mold, or byelectrical heaters attached to the mold. Electrical heaters arepreferred because of structural simplicity and easy temperature control.

With the preformed aluminum foil mold placed in the cavity of the rigidback-up mold and nested therein, a measured quantity of the chosen fluidfood that will fill the foil mold is deposited therein, and a mold topis pressed down against the back-up mold so that the foil mold and itsfood content are completely enclosed. Like the back-up mold, the moldtop is also heated. Thus, with the mold top pressed against the back-upmold, heat is rapidly transmitted to both the top and bottom of thecompressed food in the foil mold. Fluid food may be deposited in thefoil mold before or after it is nested in the back-up mold.

Temperatures in the range of about 300° F. to 500° F. are usuallychosen, depending on the food to be baked. At such temperatures and withdirect contact of the food with hot metal surfaces, the generation ofsteam and volatiles is very rapid. To prevent the build-up oftroublesome gas pressure, the mold top is permitted to pop up slightlyfor several successive instants thereby venting gases several timesduring the baking period. A needle-punctured foil mold coupled with aback-up mold that has holes therethrough provides continuous, gentleventing of gases during the baking period.

A basic and essential element of this invention is the preformed,aluminum foil mold that not only makes it possible to speed up themolding and baking of fluid food into a unified, shaped product but alsoprotects the shaped product against damage from handling and shipping.Aluminum foil, as used herein, means aluminum sheet in the gaugescommonly used to make pie pans found with boxed pies sold insupermarkets. Like such pie pans, the aluminum foil mold of thisinvention is cheap enough to be discarded when it is no longer needed.Tenneco Packaging of Lake Forest, Illinois, offers aluminum foilpreforms with “quilted bottoms” and tiny perforations which areillustrative of a preferred type of foil mold used pursuant to thisinvention.

The foil mold is always concave, usually pan-like but its bottom neednot be flat. In fact, a contoured bottom of the foil mold has beendesigned for producing pizza shells with a thickened rim in theupside-down position. Thus, when such a pizza shell has been baked, thefoil mold is inverted so that the pizza shell falls out and the flatface of the baked shell becomes its bottom with the thickened rim of theshell pointing upward. The mold top usually has a flat face forcompressing the fluid food within the foil mold, when the mold top ispressed against the back-up mold. However, the face of the mold top maybe contoured concavely or convexly to form a baked food product having adecorative pattern.

In most cases, the aluminum foil mold used in this invention is formedwith an outward flange which stabilizes the shape of the foil mold andwhich is tightly held between the back-up mold and the mold top duringthe baking period. The usual, crimped flange of an aluminum foil moldallows the escape of gases from the compressed food undergoing baking inthe closed mold. The crimped flange has tiny, radial creases throughwhich the gases leak out of the hot mold. The flange of the foil moldmay have a “curl” edge. In such case, the back-up mold and/or the moldtop will have a groove in which the “curl” fits while the mold top ispressed against the back-up mold. The back-up mold and mold top are mostfrequently made of aluminum because of reasonable cost and good thermalconductivity. Copper is a good alternative metal.

The term, fluid food, is used herein to embrace loose granular foodparticles like boxed stuffing sold in supermarkets, or pieces of cookedpasta such as linguini admixed with an aqueous binding agent, or abatter that may contain chopped nuts or whole grains, or plastic foodlike mashed potatoes or dough. Pieces of food introduced in the mold,such as cut linguini, preferably have a length not exceeding about 3inches. In short, fluid food means any food ingredients that are fluent,flowable or deformable and therefore moldable under compression.

The mold top which is alternately pressed down against the back-up moldand lifted away therefrom, can be so moved by a vertically actinghydraulic or pneumatic piston, the latter being usually preferred. Thedeposition of a measured quantity of fluid food in the foil mold whilethe mold top is lifted can be performed manually or by any knownmetering device that mechanically moves between the raised mold top andfoil mold and quickly moves away after depositing the fluid food in thefoil mold. Known timing devices are available to provide automaticmovement of the mold top and the metering device to fill the foil moldin a desired sequence repetitively.

BRIEF DESCRIPTION OF THE DRAWINGS

For further clarification of the invention, the following descriptionwill refer to the appended drawings of which:

FIG. 1 is a vertical view of a simple embodiment of the apparatus of theinvention;

FIG. 2 is an enlarged vertical section of the bottom part of theapparatus of FIG. 1;

FIG. 3 is an articulated version of the bottom part of the apparatusshown in FIG. 2;

FIG. 4 is a vertical section of only the bottom part of the apparatus ofFIG. 1 with a modified top part;

FIG. 5 is a vertical section of a modified bottom part of the apparatusof FIG. 1; and

FIG. 6 is a vertical section of a novel aluminum foil mold used with thebottom part shown in FIG. 5.

DESCRIPTION OF PREFERRED EMBODIMENTS

FIG. 1 shows the molding and baking apparatus of the invention, thebasic parts being bottom or back-up mold 10 anchored to support member11, and mold top 12 fastened to the piston rod of pneumatic cylinder 13which is suspended from overhead beam 14. Mold 10 has a cylindricalrecess 15 on its upper or molding side, designed to receive an aluminumfoil mold 18 (shown in FIG. 2). Back-up mold 10 made of aluminum haselectrical heating element 16 embedded therein but other types ofheaters may be used. Similarly, mold top 12 made of thermally conductivemetal is equipped with electrical heater 17.

FIG. 2 is a vertical section of back-up mold 10 of FIG. 1 with analuminum foil mold 18 set in cavity or recess 15. Recess 15 and foilmold 18 are shaped and dimensioned so that the outer surface of foilmold 18 contacts the surface of recess 15 as thoroughly as possible.Such close nesting of foil mold 18 in recess 15 ensures good heattransfer from back-up mold 10 to foil mold 18 and prevents distortion offoil mold 18 when food therein is being baked under compression. Foilmold 18 is formed with an outward flange 19 that stabilizes the shape offoil mold 18. After fluid food has been added to foil mold 18 and moldtop 12 has been pushed down by cylinder 13 against back-up mold 10, foilflange 19 is held firmly between mold parts 10, 12. The term nesting orany variant thereof is used herein to connote a close fitting of thefoil mold in the back-up mold like hand in glove. Some fluid foods canbe deposited in the foil mold before it is nested in the back-up mold.

With mold top 12 pressing against back-up mold 10, the fluid food infoil mold 18 is heated to a desired high temperature, say 450° F., sothat moisture and volatiles in the food generate gas pressure withinfoil mold 18. Gas pressure cannot be allowed to rise to a dangerouslevel. Flange 19 of foil mold 18 is invariably crimped so that both itstop and bottom sides have fine grooves or creases through which steamand other volatiles can seep and help reduce the build-up of a dangerouspressure within the closed mold.

As previously mentioned, foil mold 18 usually has a multiplicity ofneedle punctures or fine perforations that can vent gases generated bythe food that is being baked under compression. Gases leaving foil mold18 can travel between foil mold 18 and recess 15, and escape along theinterface of foil flange 19 and back-up mold 10. A few small holes 20extending laterally through mold 10 to the bottom of recess 15facilitate the venting of gases entering the interface of foil mold 18with recess 15. Also as previously described, mold top 17 can bepermitted to pop up for several successive instants when the food in themold generates considerable steam.

Foil mold 18 containing a unified food product at the end of a chosenbaking period can be lifted out of back-up mold 10 manually by getting apinching grasp of foil rim 19. Many schemes for facilitating the removalof foil mold 18 and the baked food therein can be visualized. Forexample, a hole passing through mold 10 to a spot below foil mold 18 canbe used to inject pressurized air and thus lift mold 18 at leastpartially out of recess 15.

In FIG. 3, back-up mold 22 has two parts: a fixed block 23 TV with alarge bore 24 in which block 25 can move up and down like a piston.Block 25 is mounted on the piston rod of pneumatic cylinder 26 which canpush block 25 up so that the top surface of block 25 is flush with, oreven above, the top surface of block 23. In short, a foil mold (notshown) placed in mold 22 as shown in FIG. 3 will be lifted out of mold22 when block 25 is pushed up by cylinder 26. Reciprocating block 25contains electrical heater 27. Fixed block 23 may also be equipped witha heater 28. The feature of two-part mold 22 of ejecting the foil moldcontaining a baked food product can also be achieved by holding block 25stationary and reciprocating block 23.

The molding face of mold top 12 of FIG. 1 is flat. With sticky foods themolding face should have a non-stick coating such as Teflon. FIG. 4illustrates that the molding face of mold top 30 need not be flat.Specifically, mold top 30 has a protrusion 31 which dips into the recess32 in back-up mold 33. Protrusion 31 is dimensioned to leave a desiredspace between it and the bottom of a foil mold (not shown) nested inrecess 32 as well as all around it. Thus, the compressed and baked foodproduct of mold top 30 and back-up mold 33 containing the foil mold hasthe form of a sheet with a thicker rim. If recess 32 and protrusion 31are cylindrical, the baked food will have the shape of a pizza shell.Recess 32 and protrusion 31 may be elliptical, square, oblong, etc.

FIG. 5 shows that back-up mold 35 can have a recess 36 of any desiredshape. The selected recess 36 has rim portion 37 which is deeper thanthe central part of recess 36.

FIG. 6 is a sectional view of preformed aluminum foil mold 38 shaped tonest in back-up mold 35 of FIG. 5. A circular form of foil mold 38 and amold top like top 12 of FIG. 1 with a flat molding face can be used toproduce upside-down pizza shells. The molding face of the mold top neednot be flat; it may have a narrow, cylinderical protrusion that fits in,and dips into, foil mold 38. The foil mold 38 will protect the pizzashell during handling and shipment. When the pizza shell is to begarnished with tomato sauce, cheese and like ingredients, the foil mold38 is inverted to release the pizza shell with its flat side down sothat the shell can be trimmed with desired condiments.

Even foil mold 38 of FIG. 6 or any other foil mold having a recess thatis not simply flat can be used with a two-part back-up mold like mold 22of FIG. 3 provided the molding face of reciprocating block 25 has acontour matching that of the foil mold. Foil mold 38 is ideally suitedfor producing pizza shells of all diameters, usually in the range of 6to 16 inches, on a rapid, continuous basis. The foil mold facilitateshandling of the pizza shell and protects it against damage duringshipment. Foil mold 18 of FIG. 2 when used with mold top 30 of FIG. 4will also yield a pizza shell that will be protected until foil mold 18is removed. Pizza shells produced in foil molds 18 and in molds 30, 33of FIG. 4 can be garnished, reheated and served without first removingfoil mold 18. Thus, foil mold 18 can also eliminate the need for aserving dish.

Pizza shells produced under compression, either face up or upside-down,in accordance with this invention are especially enjoyed by gourmetswhen formed of cooked spaghetti, linguini, fettucini and the like withan edible binding agent such as eggs or egg whites. The cooked pasta andadmixed binding agent may also contain spices, herbs and otheringredients when placed in the foil mold before being baked undercompression to form the unusual pizza shell. As is well known, a pizzashell has the shape of a pancake with a thick rim.

Variations and modifications of the invention will be apparent to thoseskilled in the art without departing from the spirit or scope of theinvention. For example, two different fluid foods, such as cooked pastaand rice may be deposited in the foil mold, side by side as separategobs, to form, when compressed and baked, a unified product, having apasta portion joined to a rice portion. Also, the back-up mold may havetwo or more cavities for the placement of a foil mold in each so thattwo or more unified products are formed in each compression and bakingcycle. Accordingly, only such limitations should be imposed on theinvention as are set forth in the appended claims.

What is claimed is:
 1. The method of compressing and baking cookedpieces of pasta admixed with a binding agent under pressure in apreformed, aluminum foil mold to form an edible, unified product, whichcomprises placing said foil mold in a back-up mold with a cavity shapedfor nesting said foil mold therein, depositing said cooked pieces ofpasta in said foil mold before or after placing said foil mold in saidback-up mold pressing a mold top down against said back-up mold, heatingsaid back-up mold and mold top to bake said cooked pieces of pasta underpressure for a period selected to convert said cooked pieces of pastainto said unified product, lifting the mold top, and removing said foilmold with said unified product therein from said back-up mold.
 2. Themethod of claim 1 wherein the preformed, aluminum foil mold is acircular, shallow pan having a deeper rim portion, so that the cookedpieces of pasta admixed with a binding agent are converted into aunified product having the shape of an upside-down pizza shell.
 3. Themethod of claim 1 wherein the preformed, aluminum foil mold is acircular, shallow pan, the mold top has a smaller, circular pan-shapedprotrusion that extends into said foil mold when said mold top ispressed down against the back-up mold to form a unified product havingthe shape of a pizza shell.
 4. The method of claim 3 wherein the cookedpieces of pasta are selected from the group consisting of spaghetti,linguini, fettuccine and noodles.
 5. The method of claim 2 wherein thecooked pieces of pasta are selected from the group consisting ofspaghetti, linguini, fettuccine and noodles.
 6. The method ofcompressing and baking fluid food under pressure in a preformed,aluminum foil mold to form an edible, unified product, which comprisesplacing said foil mold in a mold cavity shaped for nesting said foilmold therein, said mold cavity being provided by a-fixed mold ring and amold bottom reciprocable in said fixed mold ring, depositing said fluidfood in said foil mold before or after placing said foil mold in saidmold cavity, pressing a mold top down against said fixed mold ring,heating said mold bottom and mold top to bake said fluid food underpressure for a period selected to convert said fluid food into saidunified product, lifting the mold top, and pushing said mold bottom upto eject said foil mold with said unified product therein from said moldcavity.
 7. The method of claim 6 wherein the preformed, aluminum foilmold is a circular, shallow pan having a deeper rim portion so that thefluid food is converted into a unified product having the shape of anupside-down pizza shell.
 8. The method of claim 6 wherein the preformed,aluminum foil mold is a circular, shallow pan, the mold top has asmaller, circular pan-shaped protrusion that extends into said foil moldwhen said mold top is pressed down against the fixed mold ring to form aunified product having the shape of a pizza shell.
 9. The method ofclaim 8 wherein the fluid food is cooked pieces of pasta admixed with abinding agent.
 10. The method of claim 7 wherein the fluid food iscooked pieces of pasta admixed with a binding agent.